Respiratory mask sealing interface

ABSTRACT

A sealing interface forms part of an apparatus for supplying a flow of respiratory gases to a user. The sealing interface comprises a foam or gel inner cushion and a thin resilient rubber outer sheath. A face side of the inner cushion resiliently supports the outer sheath. The inner cushion has a toothed profile formed on the face side of the inner cushion. The toothed profile consists of at least one tooth having an apex on the perimeter of the inner cushion. The apex is positioned between two valleys in the perimeter of the inner cushion. In use the apex of each tooth of the toothed profile is in supporting contact with the outer sheath.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention generally relates to a sealing interface for useas part of an apparatus for supplying a flow of respiratory gases to auser.

Description of the Related Art

It is known to provide a flow of respiratory gases to a user via aninterface, such as a face mask, to relieve a number of ailments, suchas, for example, sleep apnea or snoring. One problem with supplying aflow of gases to a user via an interface, such as a face mask, is thatit can be difficult to form a good seal between the mask and the face.The mask often is held in place against the user's face by headgear wornon the user's head. In use, the head gear may be over tightened and themask is pressed uncomfortably onto the user's face. Alternatively, theheadgear may be under tightened, or applied to the user's head tooloosely, preventing the formation of an effective seal between the maskand user's face.

Prior face masks have attempted to improve the seal between the user'sface and the mask and to make the sealing interface with the user morecomfortable. U.S. Pat. No. 7,308,895 describes a mask assembly having aseal outer sheath and an inner cushion. The inner cushion has a raisednasal bridge portion that results in a more flexible seal contact on thebridge of the user's nose. The raised nasal bridge portion is formed bya cut out portion of the inner cushion with the cut-out being on a maskbody side of the cushion.

U.S. Pat. No. 6,112,746 describes a nasal mask cushion for sealing anasal mask to a user's face. The cushion has a first membrane and asecond membrane. The second membrane contacts a user's face when in use.The second membrane is thinner than the first membrane and is spacedapart from the first membrane when the mask is not in use. The secondmembrane also is spaced from the first membrane by a greater distance inthe nasal bridge region than in the cheek region.

In this specification, where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing certain features, aspects or advantages of the invention.Unless specifically stated otherwise, reference to such documents andinformation is not to be construed as an admission that such documents,or such sources of information, in any jurisdiction, are prior art, orform part of the common general knowledge in the art.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved sealinginterface, or to at least provide the industry or the public with auseful choice.

In one aspect, the present invention consists in a sealing interface foruse as part of an apparatus for supplying a flow of respiratory gases toa user comprising:

a resilient rubber outer sheath and a foam or gel inner cushion, in usethe outer sheath covering the inner cushion, the outer sheath having asheath first side, the sheath first side substantially sealing against auser's face, a face side of the inner cushion resiliently supporting atleast a portion of the sheath first side,

the inner cushion having a toothed profile in the face side of the innercushion, the toothed profile comprising at least one tooth having anapex between two valley portions in the perimeter of the face side ofthe inner cushion, in use the apex being in supporting contact with theouter sheath first side.

Preferably the toothed profile extends substantially around the fullperimeter of the inner cushion first side.

Preferably the sheath first side and the cushion first side have a nasalbridge region, either one of an upper lip region or a chin region and aleft cheek region and a right cheek region extending between the nasalbridge region and the upper lip or chin region, and a said toothedprofile is in the upper lip region or chin region.

Preferably a said toothed profile is in a lower portion of each of theleft and right cheek regions.

Preferably a said toothed profile is in nasal bridge region.

Preferably the at least one tooth has at least two converging sides,each said converging side having an angle of convergence, the angle ofconvergence being at least 30 degrees.

Preferably the tooth has a depth, the depth being approximately 3 mm to10 mm.

Preferably the tooth has a base, the base being approximately 2 mm to 20mm wide.

Preferably the at least one tooth is aligned inwards towards a centre ofthe inner cushion, a side of the at least one tooth being coterminouswith the face side of the inner cushion and an opposite side of the atleast one tooth being conterminous with an inside surface of a perimeterwall of the inner cushion, an apex of said at least one tooth beingformed where the inside surface of the perimeter wall meets the faceside of the inner cushion.

Preferably the toothed profile comprises a plurality of teeth, in useeach said tooth having an apex in supporting contact with the sheathfirst side.

Preferably each said tooth has an apex, a distance between the apex ofadjacent teeth being less than approximately 20 mm.

Preferably each said tooth has a depth, and a ratio of the tooth depthover the tooth pitch is at least approximately 0.3, wherein the pitch isthe distance between the apexes of adjacent teeth.

Preferably the tooth depth decreases as the toothed profile extends froma central position of the toothed profile to a side of the toothedprofile extending along the perimeter of the sealing interface.

Preferably the inner cushion comprises a plurality of spaced apartcushions, as said cushion being a tooth of the toothed profile.

Preferably the spaced apart cushions are joined by joining elements.

Preferably the inner cushion has at least two holes through a perimeterwall of the inner cushion, the at least two holes breaking the face sideof the inner cushion to create the at least one tooth between saidholes.

A second aspect consists in a sealing interface for use as part of anapparatus for supplying a flow of respiratory gases to a usercomprising:

a thin resilient rubber outer sheath and a foam or gel inner cushion, inuse the outer sheath covering the inner cushion, the outer sheath havinga sheath first side, the sheath first side substantially sealing againsta user's face, a face side of the inner cushion resiliently supportingat least a portion of the sheath first side,

the inner cushion having a perimeter wall, and at least two holesthrough the perimeter wall adjacent the face side of the inner cushion.

A third aspect consists in a sealing interface for use as part of anapparatus for supplying a flow of respiratory gases to a usercomprising:

a thin resilient rubber outer sheath and a foam or gel inner cushion, inuse the outer sheath covering the inner cushion, the outer sheath havinga sheath first side, the sheath first side substantially sealing againsta user's face, a face side of the inner cushion resiliency supporting atleast a portion of the sheath first side, and

at least two cavities in the face side of the inner cushion.

A fourth aspect consists in a mask assembly for use as part of anapparatus for supplying a flow of respiratory gases to a usercomprising:

a mask body having an inlet through which said flow of respiratory gasesare provided to the interior of said mask body, the inlet adapted to inuse be connected to a gases conduit, and

a sealing interface coupled to the mask body, the sealing interfacecomprising:

a thin resilient rubber outer sheath and a foam or gel inner cushion, inuse the outer sheath covering the inner cushion, the outer sheath havinga sheath first side, the sheath first side substantially sealing againsta user's face, a face side of the inner cushion resiliency supporting atleast a portion of the sheath first side,

the inner cushion having a toothed profile in the face side of the innercushion, the toothed profile comprising at least one tooth having anapex between two valley portions in the perimeter of the face side ofthe inner cushion, in use the apex being in supporting contact with theouter sheath first side.

The term “comprising” as used in this specification means “consisting atleast in part of. When interpreting each statement in this specificationthat includes the term “comprising”, features other than that or thoseprefaced by the term may also be present. Related terms such as“comprise” and “comprises” are to be interpreted in the same manner.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way ofexample only and with reference to the drawings, in which:

FIG. 1 is a block diagram of a system, such as a continuous positiveairway pressure system, for providing a heated humidified gases streamto a user as might be used in conjunction with a sealing interface thatis arranged and configured in accordance with certain features, aspectsand advantages of the present invention.

FIG. 2 is a diagram of a nasal mask that may incorporate a sealinginterface that is arranged and configured in accordance with certainfeatures, aspects and advantages of the present invention.

FIG. 3 is a cross sectional view of a face mask that may incorporate asealing interface that is arranged and configured in accordance withcertain features, aspects and advantages of the present invention.

FIG. 4a is a perspective view of a prior sealing interface innercushion.

FIG. 4b is a side view of the prior sealing interface inner cushion ofFIG. 4a , when viewed in the direction of arrow A.

FIG. 4c is an end view of the prior sealing interface inner cushion ofFIG. 4a , when viewed in the direction of arrow B.

FIG. 5a is a sealing interface inner cushion that is arranged andconfigured in accordance with certain features, aspects and advantagesof a first embodiment of the present invention.

FIG. 5b is a sealing interface inner cushion that is arranged andconfigured in accordance with certain features, aspects and advantagesof a second embodiment of the present invention.

FIGS. 6a-6e are bottom views of a face mask that show face masks thatare arranged and configured in accordance with certain features, aspectsand advantages of various embodiments of the sealing interface of thepresent invention.

FIG. 6f is a bottom view of a face mask with a prior sealing interfacearrangement having a gap between an inner cushion and an outer sheath.

FIGS. 7a and 7b show bottom views of a face mask that is arranged andconfigured in accordance with certain features, aspects and advantagesof one embodiment of the sealing interface of the present invention,wherein the chin and jaw line of two users indicated.

FIGS. 8a-8j show perspective views of various embodiments of a toothprofile for a toothed portion of a sealing interface cushion, whichembodiments are arranged and configured in accordance with certainfeatures, aspects and advantages of the present invention.

FIG. 8k is a side view of the tooth shape of FIG. 8a , when viewed inthe direction of arrow D.

FIG. 9 is a perspective view of an embodiment of a sealing interfacecushion that is arranged and configured in accordance with certainfeatures, aspects and advantages of the present invention.

FIG. 10a is a perspective view of an embodiment of a sealing interfacecushion that is arranged and configured in accordance with certainfeatures, aspects and advantages of the present invention.

FIG. 10b is a bottom view of the sealing interface cushion of FIG. 10aviewed in the direction of arrow C.

FIG. 11 is a chart showing data relating to leak rates comparing a priormask sealing interface and a sealing interface incorporating a sealinginterface cushion that is arranged and configured in accordance withcertain features, aspects and advantages of the present invention.

FIGS. 12a and 12b are charts showing a difference in compression forceused to compress the sealing interface cushion that is arranged andconfigured in accordance with certain features, aspects and advantagesof the present invention.

FIGS. 13a and 13b are perspective views of embodiments of a sealinginterface cushion that is arranged and configured in accordance withcertain features, aspects and advantages of the present invention andthat incorporates a hole profile with holes through a wall of an innercushion.

FIGS. 14a, 14c and 14d are perspective views of embodiments of a sealinginterface cushion that are arranged and configured in accordance withcertain features, aspects and advantages of the present invention andthat incorporates holes or cavities in a side of the sealing interfacecushion that faces a user's face in use.

FIG. 14b is a cross sectional view of the sealing interface cushion ofFIG. 14a , when viewed in the direction of arrows A.

FIGS. 15a, 15b, 15d and 15e are perspective views of embodiments thatare arranged and configured in accordance with certain features, aspectsand advantages of the present invention, wherein the sealing interfacecushion comprises a plurality of spaced apart cushions.

FIG. 15c is a perspective view of an embodiment that is arranged andconfigured in accordance with certain features, aspects and advantagesof the present invention, wherein the sealing interface cushioncomprises spaced apart cushions joined together by joining elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A sealing interface that is arranged and configured in accordance withcertain features, aspects and advantages of the present inventionprovides improvements in the delivery of CPAP therapy. In particular asealing interface is described that reduces a pressure of a mask on aface of a user and that reduces leakage when compared with the priorart. The sealing interface as described herein can be used inrespiratory care generally or with a ventilator but will be describedbelow with reference to use in a humidified CPAP system. Certainfeatures, aspects and advantages of the present invention can be appliedto any form of interface including, but not limited to, full face masksthat seal around a nose and a mouth of a user, nasal masks that sealaround a nose of a user, and oral masks and mouthpieces that are insealing engagement with a mouth of the user.

With reference to FIG. 1 a humidified Continuous Positive AirwayPressure (CPAP) system is shown in which a user 1 is receivinghumidified and pressurized gases through an interface 2 that isconnected to a humidified gases transportation pathway or inspiratoryconduit 3. Delivery systems could also be VPAP (Variable Positive AirwayPressure), BiPAP (Bi-level Positive Airway Pressure) or any of numerousother forms of respiratory therapy. An inspiratory conduit 3 isconnected to the outlet 4 of a humidification chamber 5, which containsa volume of water 6. The inspiratory conduit 3 may contain heating meansor heater wires (not shown) that heat the walls of the conduit to reducecondensation of humidified gases within the conduit 3. Thehumidification chamber 5 preferably is formed from a plastics materialand may have a highly heat conductive base (for example, an aluminumbase) that is in direct contact with a heater plate 7 of a humidifier 8.The humidifier 8 is provided with control means or an electroniccontroller 9 that may comprise a microprocessor-based controller thatexecutes computer software commands stored in an associated memory.

The controller 9 receives input from sources, such as user input meansor a dial 10 through which a user of the device may, for example, set apredetermined required value (e.g., preset value) of humidity ortemperature of the gases supplied to user 1. The controller 9 also mayreceive input from other sources, such as, for example, temperatureand/or flow velocity sensors 11, 12 through a connector 13 and a heaterplate temperature sensor 14. In response to the user set humidity ortemperature value, which is input via the dial 10, and the other inputs,the controller 9 determines when, or to what level, to energise theheater plate 7 to heat the water 6 within the humidification chamber 5.As the volume of water 6 within the humidification chamber 5 is heated,water vapor begins to fill the volume of the chamber 5 above the water'ssurface and the water vapor is passed out of the outlet 4 of thehumidification chamber 5 with the flow of gases (for example, air) thatis provided from a gases supply means or a blower 15, which flow entersthe chamber through an inlet 16. Exhaled gases from the mouth of theuser can be passed directly to ambient surroundings in FIG. 1.

The blower 15 can be provided with variable pressure regulating means ora variable speed fan 21 that draws air or other gases through a blowerinlet 17. The speed of the variable speed fan 21 is controlled by anelectronic controller 18 (or alternatively the function of thecontroller 18 could carried out by the controller 9) in response toinputs from the controller 9 and a user-set predetermined required value(e.g., preset value) of pressure or fan speed, which is set via a dial19, for example.

Interface

An interface in the form of a nasal mask 2 is shown in FIG. 2. The mask2 comprises a hollow body 22 with an inlet 23 that is connected to theinspiratory conduit 3. The mask 2 is positioned around the nose of theuser 1 with headgear 25 secured around a back of a head of the user 1. Arestraining force from the headgear 25 on the hollow body 22 and aforehead rest 26 provides sufficient compressive force on a mask seal100 to provide an effective seal against the face.

The hollow body 22 is constructed of a relatively inflexible material,such as, for example, polycarbonate plastic. Such a material wouldprovide a desired rigidity, would be transparent and would be arelatively good insulator. The expiratory gases can be expelled througha valve (not shown) in the mask 2, a further expiratory conduit (notshown), vent paths through the mask 2 (not shown), or any other suitablemethod.

Mask Seal

The mask seal 100 is provided around a periphery of the mask body 22.The mask seal 100 provides an effective seal onto the face of the userto reduce the likelihood of leakage. The mask seal 100 is shaped toapproximately follow the contours of the face of the user. The seal iscontoured to approximately match the facial contours of the user aroundthe nose, from a bridge of the nose, continuing down the cheek regionsadjacent each side of the nose and across a philtrum area of the user(i.e., where a nasomedial and maxillary processes meet). Similarly, ifthe seal 100 was applied to a full face mask covering a user's nose andmouth, the seal would be shaped to approximate the facial contours ofthe chin and wider cheek regions. The seal 100 will deform when pressureis applied by the headgear 25 to adapt to individual contours of mostusers.

A prior full face mask assembly and mask seal arrangement for sealingaround the nose and the mouth of the user is shown in FIG. 3. Theillustrated mask seal 100 comprises an inner foam cushion 101 covered byan outer sealing sheath 102. The inner cushion 101 is constructed of aresilient material, such as, for example, polyurethane foam, todistribute pressure along the seal 100 around the face. In other forms,the cushion 101 may be formed of other appropriate materials, such as agel material, for example.

One side of the illustrated inner cushion 101 is shaped to approximatelymatch the shape of the face of the user. As shown in FIG. 4, the innercushion 101 can comprise an indented section 54 that is intended to fitover the bridge of the nose of the user, a cheek contour 55 on each sideto follow the cartilage extending from the middle of the nose of theuser, and an indented section 56 to seal around the chin area of theuser. An opposite side of the cushion 63 is shaped to match andinterface with the mask body 22.

The inner cushion 101 may include a raised bridge 65 in the nasal bridgeregion. The raised bridge 65 can also be described as a valley formed inthe cushion 101 on a mask body side 63 of the cushion. Because theraised bridge 65 is unsupported by the mask body 22, it is much moreflexible and results in less pressure on the nasal bridge of the user.In other forms, the cushion may have other bridge portions, so that inthese bridging areas the cushion 101 is more flexible.

The inner cushion 101 is located around an inner periphery 103 of anopen face 104 of the hollow body 22. The inner cushion 101 contacts themask body, except for in the raised bridge portion 65. As best shown inFIG. 3, the cushion is located in a cavity 66 that extends around theinner periphery 103 of the body 22. The cavity 66 terminates at eachside of the nose bridge region 67 of the mask, where the raised bridgeportion 65 of the cushion generally does not contact the mask body 22.The cavity 66 generally is formed by two spaced apart walls 76, 77 thatextend around the inner periphery of the mask.

Similarly, the outer sheath 102 is attached to an outer periphery of themask body 22, either directly to the body 22 in a push fit arrangementas shown in FIG. 3 or indirectly via a mask seal clip (not shown), forexample. Preferably, a side of the outer sheath 102 is attached to aseal clip (not shown). The seal clip interfaces with the mask body 22.The clip provides a releasable rigid or semi rigid interface, whichallows the seal to be easily attached and detached from the mask bodymany times. The outer sheath 102 surrounds and loosely covers over thetop of the inner cushion 101.

One side of the outer sheath 102 also is shaped to match the facialcontours of the face of the user. The outer sheath preferably closelymatches the shape of the side of the inner cushion 101 adjacent the faceof the user in use.

Preferably, the inner cushion 101 is a separate item with the outersheath 102 fitting in place over the inner cushion 101. In the preferredembodiment, the outer sheath 102 holds the inner cushion 101 in placewithin the mask assembly 2. Alternatively, the inner cushion 101 may bepermanently or releasably attached to the outer sheath 102 so that theouter sheath 102 and the inner cushion 101 may be provided as a singleassembly. Alternatively, the inner 101 cushion may be permanently orreleasably attached to the mask body 22. In a further alternative, theouter sheath 102 and the inner cushion 101 may be integrally formed.

Toothed Profile

As shown in FIGS. 5 to 7, certain features, aspects and advantages ofthe present invention can be exemplified in a mask cushion designed foruse in a mask assembly, such as the mask assembly described above. Likethe inner cushion of the prior sealing interface, the inner cushion 101that is arranged and configured according to certain embodiments of thepresent invention is constructed of a resilient material, preferablypolyurethane foam, to distribute pressure along the seal around the faceof the user. In other forms, the present cushion 101 may be formed ofother appropriate materials, such as a gel material, for example. Theinner cushion 101 may be formed from any suitable resilient materialhaving similar stiffness to a two part polyurethane foam with a densityof approximately 0.20-0.25 g/cm3.

The outer sheath 102 is a thin resilient rubber material that is used toform a seal against the face of the user in use. Preferably, the outersheath 102 is formed from silicone.

The mask cushion 101, when arranged and configured in accordance withcertain features, aspects and advantages of one embodiment of thepresent invention, has a toothed profile 110 on the side of the cushion101 that bears against face of the user when in use. The outer sheath102 would be located between the face of the user and the toothedprofile during in use. One significant advantage of such a constructionis that the valleys 112 of the toothed profile 110 are on the user faceside 109 of the cushion.

Having the toothed profile 110 on the face side of the cushion 101 isbelieved to result in an improved seal for a given sealing force. Tocreate an effective seal on the face, the head gear 25 is tightenedsufficiently to compress the cushion 101 against the face. The toothedprofile 110 helps achieve an effective seal using a lower sealing forcethan a similar inner cushion without the toothed profile 110. Thisresults in a more comfortable interface. A user can use the mask 2 witha lower sealing force, such that the headgear and the mask assembly canbe applied to the head and face with less tension in the head gearstraps, which results in a lower compressive force of the seal 100 onthe face. The lower compressive force results in less irritation over anextended use period. With less irritation, users are more likely to usethe mask and to adhere to treatment requirements. Thus, increasedcompliance results from the improved cushion structure.

Some prior masks comprise a gap between the outer sheath 102 and theinner cushion 101 as shown in FIG. 6f . The mask of FIG. 6f is shownwhen not in use. In use, the gap between the outer sheath 102 and theinner cushion 101 may or may not close, depending on the sealing forceapplied to the sealing interface. However, an improvement has beendiscovered. Providing discrete points or areas 114 of support for theouter sheath when in use is believed to improve the performance of themask. The contact support points or areas are spaced apart along theperimeter of the mask sealing interface.

The illustrated toothed profile consists of at least one tooth 111having an apex 114 on the perimeter of the cushion. The apex 114 ispositioned between two valleys 112 in the perimeter of the cushion 101.The at least one tooth 111 is formed in the face side 109 of theillustrated cushion.

The at least one tooth 111 comprises a base 113, which is indicated bythe dashed line in FIG. 6a , and the apex 114. The toothed profileachieves an improved seal by allowing for an increased amount ofcompression of the cushion for a given force, due to the reduced bearingsurface area of the face side of the cushion compared to a cushionhaving no valleys 112. Furthermore, the apex 114 of the at least onetooth 111 may deflect relatively easily in any direction laterallyacross the face (i.e., vertically on the face, horizontally on the face,or any other direction across the face). In the cushion that is shown inFIG. 3, a particular point on the face side of the cushion cannotdeflect sideways as easily due to support provided in the cushionmaterial adjacent that point. Having contact points or areas 114 incontact with the outer sheath 102 provides improved flexibility of thecushion and an improved level of fit for a given sealing force.

Due to the differing facial contours of different users, to achieve aneffective seal on any given face, the seal should conform to aparticular face easily. For example, when considering the shape of thechin region, one chin may be relatively broad and another chin may berelatively narrow. As shown in FIG. 7a , a first chin and jaw line isindicated by the dashed line 120. In order to conform to the line 120,each tooth 111 must be significantly compressed. Due to the reducedbearing area of the face side of the cushion comprising the toothedprofile, the force required to press the seal 100 against the first chinand jaw line is lower than for a cushion without the toothed profile.FIG. 7b shows a second chin and jaw line 121, which is broader than thefirst chin and jaw line 120. In order to conform to a broader chin, thecentral portions of the toothed profile do not require as muchcompression. However, the apex 114 of the teeth 111 of the toothedprofile 110 provides contact support against the outer sheath 102 atpositions around the periphery of the mask seal 100. The toothed profile110 provides more contact points than the prior art seal arrangement ofFIG. 6f , and these contact points deflect and compress more easily thana prior art inner cushion without a toothed profile. Teeth that requirea relatively high level of compression to conform to a user's face, asshown in FIG. 7a , will compress more easily compared to a cushionwithout a toothed profile. Teeth that require a relatively low level ofcompression or substantially no compression, as shown in FIG. 7b maystill maintain contact with and provide support to the outer sheath. Thetoothed profile therefore provides an improved fit against a range ofusers with different facial contours.

The toothed profile achieves points of contact between the inner cushion101 and the outer sheath 102 along the sealing interface perimeter. Asthe sealing interface is compressed against the face, the outer sheath102 is stretched over the contact points and bridges the gaps betweenthe contact points. The seal, at positions where the outer sheath 102bridges valleys between teeth contact points, is relatively easy todeflect or compress a given amount of compression. The seal, where teethcontact the outer sheath 102, requires a higher level of force tocompress for the same amount of compression.

The improvement in sealing efficiency of a seal interface incorporatingthe toothed inner cushion 101 is indicated in FIG. 11. FIG. 11 is achart displaying the sealing efficiency of a sealing interfaceincorporating an inner cushion with a toothed profile compared to thesealing effciencies of a sealing interface incorporating the same innercushion but without a toothed profile. As shown in FIG. 11, a lowerheadgear strap force (i.e., a lower tension in the strap), which resultsin a lower mask seal force against the face of the user, is required toachieve a given leak rate. The upper trend line in FIG. 11, which islabelled 300, reflects data collected for a sealing interface comprisingan inner cushion without a toothed profile. The lower trend line in FIG.11, which is labelled 301, reflects data collected for a sealinginterface comprising an inner cushion with a toothed profile in the faceside of the inner cushion. For example, for a leak rate of about 10litres per minute, the toothed cushion sealing interface requires astrap tension of less than about 2 Newtons while the same mask assemblyincorporating the same inner cushion but without a toothed profilerequires more than about 4 Newtons of strap force to reduce the leakrate to about 10 litres per minute. The data presented in FIG. 11 isaveraged data collected from a range of different facial shapes.

The effect of the toothed profile also can be seen in FIGS. 12a and 12b. A Newton meter fitted with a cone tip was used to measure the forcerequired to compress the sheath and cushion of the seal 100 by a setdistance. The cone tip used with the Newton meter had a base diameter ofapproximately 10 mm and a height of approximately 5 mm. Thus, the anglebetween the side of the cone tip and a plane perpendicular to the axisof the cone tip was about 45 degrees. The bars of each chart labelledwith even numbers relate to positions along the mask seal at the apexes114 of the toothed profile of the mask cushion 101. The bars labelledwith odd numbers relate to positions along the mask seal 100 in betweenthe apexes of the teeth of the toothed profile.

FIG. 12a shows a bar chart of the force required to compress differentpositions of the mask seal 100 by 3 mm. To compress the seal by 3 mm atthe apex of a tooth requires a force of 1.5N. To compress the seal by 3mm at positions where the sheath is initially unsupported by the cushion101 (i.e., where the sheath is located over valleys 112 of the maskcushion 101), requires a force of around 0.25N. FIG. 12b shows the samebar chart as FIG. 12a but for a compression of the mask seal 100 by 6mm.

The force required to compress a point on the seal 100 comprising thecushion without the teeth is similar to the force required to compressthe seal at the apex 114 of the tooth for the seal with the cushion 101having the toothed profile 110. For example, to compress a point on theseal, the seal having the sheath and the cushion without teeth, by 6 mmwill require approximately 2.5N of force.

The charts of FIGS. 12a and 12b show how the overall force required tocompress the seal 100 of the mask is reduced with the introduction ofthe toothed profile, while the toothed profile maintains support for thecushion at different points along the perimeter of the seal. Also, thecharts of FIGS. 12a and 12b show how the differences between forces atdifferent points change with increased compression. As the amount ofcompression of the seal 100 is increased, the ratio of the force tocompress the seal at the tooth over the force to compress the seal atthe cushion gap 112 reduces. For example, for the 3 mm compression shownin FIG. 12a , the ratio is 6 (i.e., the force required to compress theseal at the tooth is six times the force required to compress the sealat the tooth gap), with the outer sheath 102 in contact with the cushion101 at the apexes 114 of the toothed profile. For the compression of 6mm shown in FIG. 12b , the force required to compress the seal at thetooth is 2.5 times the force required to compress the seal at the toothgap, with the outer sheath 102 in contact with the cushion 101 at theapexes of the toothed profile. As the amount of seal compressionincreases further, the ratio tends towards 1.

FIGS. 6a through 6e are bottom views of face masks incorporating variousembodiments of the sealing interface 100 with the sealing interface inthe uncompressed state. The sealing interface 100 is in the uncompressedstate when not being used. FIGS. 6a to 6e show the sheath 102 and thecushion 101 generally spaced apart when in the uncompressed state.However, the apex 114 of any one or more teeth 111 may contact the outersheath 102 when the interface seal 100 is in the uncompressed state,with the valley areas 112 not contacting the outer sheath 102.

The toothed profile 110 may comprise a single tooth, as shown in FIG. 6b. Alternative embodiments may include two, three, or more teeth, asshown in FIGS. 6c to 6e . The preferred embodiment has a toothed profilein the chin region consisting of at least about four teeth, as shown inFIG. 6a . Each tooth can be formed on the side 109 of the cushion thatbears against the face of the user when in use.

Various tooth profiles are shown in FIGS. 8a to 8j . The at least onetooth preferably comprises four sides 116 as shown in FIGS. 8b, 8d, 8e,8h, 8i and 8j with the four sides 116 converging from the base 113 tothe apex 114. The apex 114 may be formed by the four sides 116converging to a point, as shown in FIG. 8b . Alternatively, the toothmay have two converging sides and two substantially parallel sides 117,as shown in FIGS. 8a, 8c and 8g , such that the apex is formed as aridge 108, 118. The inner cushion of FIG. 5b comprises a toothed profile110 with teeth 111 having a profile similar to the profile of FIG. 8a .Alternatively, the tooth may have four converging sides, with twoopposing sides 119 converging at a lower angle of convergence comparedto the other two opposing sides 116, such that the apex is formed as aridge 118, as shown in FIGS. 8d and 8i . Alternatively, the base 113 ofthe tooth may be substantially rectangular, such that a ridge apex 118is formed with four sides converging at the same angle.

Preferably, the apex 114, 118 is truncated to form an apex having anarea 108 substantially reduced compared to the area of the base 113, asshown in FIGS. 8c, 8e, 8g, 8h and 8j . The inner cushion of FIG. 5acomprises a toothed profile 110 with teeth 111 in a lower portion of thecheek regions 55 of the inner cushion 101 having a profile similar tothe profile of FIG. 8j . Alternatively, the tooth may be substantiallyfrustoconical in shape, as indicated in FIG. 8f . Apex area 108 of thetooth of FIG. 8f may be rounded, similar to the tooth profile of FIG. 8j, for example.

The tooth profiles shown in FIGS. 8a to 8j may be symmetrical about afirst plane and a second plane, the first plane being in line with theridge 118 of FIG. 8a and the second plane being in line with the ridge118 of FIG. 8d . Alternatively, the tooth 111 may have an asymmetricalshape, being symmetrical about one plane only, with the apex 114, 119offset to one side of the tooth 111. The inner cushion 101 of FIG. 5acomprises a toothed profile 110 with teeth 111 in a chin region 56 ofthe inner cushion 101, wherein the teeth have a shape with the apex 114being offset towards an outside surface of the inner cushion 101 (i.e.,the outside surface at the bottom of the cushion, which is obstructedfrom view in FIG. 5a ). Alternatively, the toothed profile 110 maycomprise teeth having a shape with the apex 114,119 offset to two sidesof the tooth 111, such that the tooth is asymmetrical with respect tothe first and second planes described above.

As shown in FIGS. 8a through 8f , the sides 116, 117, 119 may be planar.Alternatively, as shown in FIGS. 8g through 8j , the sides 116, 119 maybe convex or concave.

Any one or more combinations of the tooth shapes identified in FIG. 8athrough FIG. 8j may be incorporated into the toothed profile of theinner cushion. Alternatively, the toothed profile 111 may include teethwith other shapes.

A preferred embodiment of the inner cushion 101 is shown in FIG. 9. Thepreferred toothed profile 111 of FIG. 9 comprises teeth 111 similar inshape to the teeth of FIG. 8h . However, the tooth profiles of FIGS. 8athrough 8i are generally aligned centrally on the edge 109 of the innercushion 101, as in the embodiments of FIGS. 5a and 5b . In the preferredembodiment of FIG. 9, the toothed profile 110 in the chin region 56(refer to FIG. 4a ) of the cushion 101 is formed by valleys 112 formedthrough the face side area 109 and inside surface 105 of the perimeterwall of the inner cushion 101. The valley portions 112 do not extendsignificantly through the outside surface 106 of the perimeter wall ofthe inner cushion. The teeth 111 in the chin region therefore generallyare aligned inwards towards a centre of the inner cushion; one side 119of the tooth 111 generally is coterminous with the inner surface 105 ofthe inner cushion, the other side 119 of the tooth generally iscoterminous with the surface of edge 109. The apex area 108 of the tooth111 is formed where the inner surface 105 meets the surface of edge 109.Sides 116 of the tooth 111 generally are coterminous with sides of thevalley portions 112 on either side of the tooth 111.

The teeth 111 formed in the lower section of the cheek regions 55 of thecushion in FIG. 9 are formed in a similar way to the teeth in the chinregion 56. Valley portions 112 are formed in the edge 109 without valleyportions 112 significantly extending through the outer surface 106 ofthe cushion 101. Due to a curved shape of edge 109 in the lower cheekregion, the apex 108 is located more outwardly compared to the apex 108of the teeth 111 in the chin region 56, and sides 119 of the teeth inthe lower cheek regions generally are coterminous with the curvedsurface of the edge 109 of the cushion, as shown in FIG. 9.

In the alternative embodiment of FIG. 10, the toothed profile consistsof a comb type profile, where the bearing surface area of the edge 109of the cushion is reduced by forming a series of teeth, steps orfingers, 125 in the edge 109. In one embodiment, the width of each tooth126 is approximately equal to the width of each gap 127 between eachtooth 126. In this embodiment, the bearing surface area of the cushionedge 109 is halved to reduce the compression force required to conformthe cushion to the facial profile of a user. Alternatively, each gap 127may be wider than each tooth 126 to decrease the bearing surface areaeven further. In an alternative embodiment, the width of each tooth maybe wider than the width of each gap 127. In a further alternativeembodiment, the tooth width and the gap width may vary for differentsections of the edge 109 of the cushion, to result in portions of thecushion that are more easily compressed compared to other portions.

For example, the gaps 127 in the nasal bridge region may be morefrequent than in other regions of the sealing interface to reduce thesealing force on the bridge of the nose of the user. The gaps 127 may belarger in the nasal bridge region than in other regions of the sealinginterface to reduce the sealing force on the bridge of the nose of theuser.

The width of the gaps 127 or the widths of the teeth 126 may vary aroundthe perimeter of the sealing interface. The width of the tooth or thefinger 125 may be chosen to be thin enough to allow buckling of thetooth under normal compression forces achieved during use. As the teeth125 buckle under normal loads, the teeth provide a reduced level ofsupport to the outer sheath, which allows improved conformance.

Preferably, the sealing interface comprises an inner cushion with anyone of the toothed profiles described above in the chin region of thecushion. Preferably, the toothed profile consists of four teeth 111 orfive valley portions 112 in the chin region, as shown in FIG. 9.Preferably, the sealing interface has an inner cushion with any one ofthe toothed profiles described above extending into a lower section ofeach cheek portion of the cushion. Preferably, the toothed profileconsists of two teeth in the lower portion of each cheek region, asshown in FIG. 9.

Alternatively, the toothed profile may extend around the full perimeterof the cushion. In a further alternative embodiment, the cushion mayincorporate the toothed profile in the nasal bridge region.

Preferably, the toothed profile has multiple teeth with a distancebetween the apexes of adjacent teeth of approximately 5 mm to 25 mm.Preferably, the distance between the apexes of adjacent teeth is lessthan about 20 mm. Most preferably, the distance between adjacent toothapexes is less than about 15 mm. The depth of a tooth 111 (i.e., thedistance between the apex 114 and the base 113) is approximately 3 mm to10 mm. Preferably, the tooth depth is about 5 mm to 10 mm. The width ofthe base 113 of a tooth 111 can be approximately 2 mm to 25 mm.Preferably, the width of the base 113 of a tooth 111 is approximately 2mm to 20 mm. Most preferably, the width of the base 113 of a tooth 111is less than 15 mm.

The angle of convergence 115 as shown in FIG. 8k can be high enough toprovide a significant reduction in bearing surface area of the side 109of the cushion that faces the face of the user in use. For example, anangle of convergence 115 of zero means that no teeth are formed in theside 109 of the cushion 101. Preferably, the angle of convergence isgreater than about 35 degrees. Most preferably, the angle of convergenceis greater than about 45 degrees.

The distance between the apexes of adjacent teeth may be described asthe tooth pitch of the toothed profile. In the preferred embodiment, theratio of the tooth depth over the tooth pitch is at least approximately0.3. That is, the pitch is less than approximately three times thedepth. Most preferably, the ratio of the depth and pitch is at leastabout 0.5 (i.e., the pitch is less than approximately twice the depth).

The cushion 101 preferably has a toothed profile 110 with a decreasingtooth depth as the toothed profile 110 extends from a central positionof the toothed profile portion to an edge of the toothed profileportion, such as the construction shown in FIG. 6 a.

The dimensions of the teeth of the toothed profile described above helpachieve an improved seal. To seal in and around finer features anddetailed contours of the face of the user, the relatively small pitchand high depth of the teeth perform well in sealing into creases andlines in the face of the user, such as smile lines and creases aroundthe mouth and between the nose and cheek area of the user.

Certain features, aspects and advantages of the present invention may beimplemented in a mask assembly having an integral cushion and outersheath. However, the embodiments having an integrally formed cushion andouter sheath may not be preferred because the amount of movement betweenthe outer sheath and the inner cushion is limited compared to when aseparate cushion and outer sheath are used. Having a separate sheath andcushion provides relative movement between the sheath and the cushionresulting in an improved fit compared to if the sheath and cushion aresecured together in an integrated construction.

Plurality of Spaced Apart Inner Cushions

In an alternative embodiment shown in FIGS. 15a and 15b , the maskcushion 101 may be a plurality of cushions 1001 spaced apart to achievea toothed profile generally comprising teeth 1011 and gaps 1012 betweenthe teeth 1011.

Each cushion 1001 has a side 1009 that bears against the face of theuser in use. As shown in FIG. 15b , side 1009 of at least one cushion1011 may be shaped as previously described in relation to FIGS. 8a to 8jor may have any other suitable toothed profile, including any describedherein.

The cushion 101 may comprise a plurality of cushions 1001 in the chin orupper lip region, the cheek regions, nasal bridge region, or completelyaround the perimeter of the mask seal 100.

The embodiment of FIG. 15a is similar in concept and operation to theembodiment shown in FIGS. 10a and 10b . For example, the removedportions 127 of the cushion of FIG. 10a may be removed to a sufficientdepth such that, under normal operation, the mask seal 100 is notcompressed further than the depth of the removed portions 127.

In the alternative embodiment of FIG. 15c , the plurality of cushions1001 may be attached to one another to form a single cushion comprisingcushion elements 1001 joined together by joining elements 1013. Thecushion elements 1001 are sized to extend between the mask hollow body22 and an inner surface of the side of the outer sheath that bearsagainst the face of the user in use. The joining elements are sized tonot extend between the hollow body 22 and the side of the outer sheaththat bears against a user's face in use. The joining elements 1013 maybe located to contact the outer sheath. For example, the joiningelements 1013 may contact an inner surface of the side of the outersheath that seals against the face of the user in use. In this case, thejoining elements 1013 are sufficiently thin to result in a low force fora given amount of seal compression at a joining element 1013 compared tothe force required to compress the seal by the same amount ofcompression at a cushion element 1001. Alternatively, the joiningelements 1013 may be located to not contact the outer sheath.

Further embodiments are illustrated in FIGS. 15d and 15e . In theembodiment of 15 d, the inner cushion 102 comprises a plurality ofcushions 1001 spaced apart around the full perimeter of the sealinginterface with gaps 1012 between adjacent cushions 1001. In theembodiment of FIG. 15e , the individual cushions 1001 are arranged suchthat a gap 1012 is located in the nasal bridge region of the sealinginterface.

The perimeter length of the gaps 1012 between the plurality of cushions1001 may be varied to result in portions of the cushion that are moreeasily compressed compared to other portions.

Hole Profile

In a further alternative embodiment, as shown in FIG. 13b , a toothedprofile in the face side of the inner cushion can be achieved by holes140 that extend through the wall 107 of the inner cushion. The holesbreak the surface of the face side 109 of the inner cushion.

In the alternative embodiment of FIG. 13a , the holes 140 through thewall 107 of the inner cushion do not break the surface of the face sideof the cushion. The holes 140 are provided near the side 109 that bearsagainst the face of the user. The portions 141 adjacent to the holes 140compress more easily compared to the portions 142 located between theadjacent holes 140. The holes 140 may be circular or have any othersuitable shape, such as oval as shown in FIG. 13a , for example.

In an alternative embodiment of FIGS. 14a and 14b , the holes orcavities 160 are provided in the side 109 of the cushion that bearsagainst the face of the user in use. The cavities result in portions ofthe seal 100 that compress more easily compared to portions of the sealat positions of the cushion 161 in between the cavities 160.

The cavities 160 may vary in perimeter length around the perimeter ofthe inner cushion to result in portions of the cushion perimeter thatare more easily compressed compared to other portions, as shown in FIG.14d . The cavities 160 may vary in depth around the perimeter of theinner cushion to result in portions of the cushion that are more easilycompressed compared to other portions, as shown in FIG. 14b . Thecavities 160 may vary in width across the side 109 of the cushion aroundthe perimeter of the inner cushion to result in portions of the cushionthat are more easily compressed compared to other portions, as indicatedin FIG. 14d , for example.

The areas 161 between and around the cavities 160 may form a continuouscontact surface in contact with the outer sheath. The cavities 160 mayhave an asymmetric shape as indicated in the cross sectional view ofFIG. 14 b.

The cavities 160 may be positioned around the full perimeter of thecushion, with each cavity being spaced apart by the areas 161 betweenthe adjacent cavities, as shown in FIG. 14c . Alternatively, thecavities 160 may only be provided in particular regions of the cushion.For example, the cavities 160 may be provided in the upper lip region ofthe cushion.

The perimeter length of spacing 161 between the cavities 160 may bevaried. Alternatively, spacing between the cavities 160 may have equallength around the perimeter of the inner cushion.

A sealing interface comprising an inner cushion with a toothed profileon the face side of the inner cushion supporting an outer sheathachieves an improved sealing interface having a reduced leak rate for agiven interface headgear strap tension compared to prior sealinginterfaces.

Certain features, aspects and advantages of the present invention havebeen described with reference to a number of embodiments. It is to beunderstood that these embodiments are merely illustrative. Modificationsmay be made thereto without departing from the scope of the invention.

What is claimed is:
 1. A mask cushion constructed of a resilientmaterial for use as part of an apparatus for supplying a flow ofrespiratory gases to a user, the mask cushion comprising: a toothedprofile in a face side of the cushion, the toothed profile comprising atleast one tooth having an apex between two valley portions in the faceside of the cushion, the at least one tooth has at least two convergingsides, each converging side having an angle of convergence of at least30 degrees, wherein the at least one tooth is aligned inwards towards acentre of the cushion, a side of the at least one tooth is coterminouswith the face side of the cushion, an opposite side of the at least onetooth is coterminous with an inside surface of a perimeter wall of thecushion and the apex of the at least one tooth is formed where theinside surface of the perimeter wall meets the face side of the cushion.2. The cushion of claim 1, wherein the face side has a nasal bridgeregion, either one of an upper lip region or a chin region, and a leftcheek region and a right cheek region, each of the left and right cheekregions extending between the nasal bridge region and the upper lip orchin region, and the at least one tooth that is aligned inwards towardsa centre of the cushion is in the upper lip region or chin region. 3.The cushion of claim 2, further comprising a second toothed profile in alower portion of each of the left and right cheek regions, the secondtoothed profile comprising at least one tooth in each of the left andright cheek regions.
 4. The cushion of claim 3, wherein, due to a curvedshape of an edge of the cushion in the lower portion of the left andright cheek regions, an apex of the at least one tooth in each of thelower portion of the left and right cheek regions is located moreoutwardly compared to the apex of the at least one tooth in the upperlip or the chin region.
 5. The cushion of claim 4, wherein, due to thecurved shape of the edge of the cushion in the lower portion of the leftand right cheek regions, sides of the at least one tooth in each of theleft and right cheek regions are coterminous with the curved shape ofthe edge of the cushion.
 6. The cushion of claim 1, wherein the toothedprofile extends substantially around a full perimeter of the face sideof the cushion.
 7. The cushion of claim 1, wherein said toothed profileis in a nasal bridge region.
 8. The cushion of claim 1, wherein the atleast one tooth has a depth of approximately 3 mm to 10 mm.
 9. Thecushion of claim 1, wherein the at least one tooth has a baseapproximately 2 mm to 20 mm wide.
 10. The cushion of claim 1, whereinthe at least one tooth comprises at least two teeth, each of the atleast two teeth having an apex, and a distance between the apexes ofadjacent teeth is less than approximately 20 mm.
 11. The cushion ofclaim 10, wherein each of the at least two teeth has a tooth depth and aratio of the tooth depth over a tooth pitch is at least approximately0.3, wherein the tooth pitch is the distance between the apexes ofadjacent teeth.
 12. The cushion of claim 11, wherein the tooth depthdecreases as the toothed profile extends from a central position of thetoothed profile to a side of the toothed profile extending along theperimeter of the cushion.
 13. The cushion of claim 1, wherein thecushion is formed from a foam or gel material.